Easy access woven plastic bags

ABSTRACT

A woven laminated plastic bag having a weakened portion is provided. The weakened portion is generally defined by a plurality of perforations in the bag. In various aspects the bag can be fabricated from woven polypropylene and/or polyethylene layer which can be laminated with a film layer, can form a pinch bottom bag, and can have one or both sides include graphics and/or printing. The bag can also provide a top end and/or a bottom end either or both of which provide a discrete area which may contain discrete graphics and/or printing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims the benefit of priorityof U.S. patent application Ser. No. 14/159,737, which was filed on Jan.21, 2014, and which claims the benefit of priority of U.S. ProvisionalPatent Application Ser. No. 61/755,322, filed on Jan. 22, 2013, both ofwhich are incorporated herein by reference in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

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THE NAMES OF PARTIES TO A JOINT RESEARCH AGREEMENT

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INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC

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BACKGROUND OF THE INVENTION 1. Field of the Invention

The present disclosure relates to plastic bags with improved openingfeatures.

2. Background of the Invention

Conventional plastic bags of a wide variety of size and shape are usedin various situations. Bulk materials, such as flour, sugar, rice, seed,animal feed, chemicals, powdered materials or the like, for example,typically have been packaged in woven plastic bags in the past. Petfood, bird seed and other products sold in retail stores typically havenot been packaged in conventional woven plastic bags. Among otherreasons for this, woven plastic bags were considered too rudimentary tobe printed with high end graphics suitable for consumer type ofpackaging. In addition, the high speed requirements in the filling andpackaging operations limited the use of the woven bags in theseapplications.

Laminated woven sacks (LWS) were developed using a woven polypropylenestructure laminated to a bi-oriented polypropylene film (BOPP) that canbe reverse printed with high end graphics suitable for consumer type ofpackaging. The LWS provides a stronger, more attractive bag than themore conventional multiwall bags used for that purpose over the last 20years. Due to their tough strong structure, conventional LWS bags aretypically sewn shut on both ends. These LWS recently met with successand have been successfully substituted for the conventional multiwallpaper bags used in the pet food industry for many years.

One major drawback of the sewn LWS has been the closing of the bags athigh speed filling lines, such as those for filling such bags with petfood. Experience has shown that sewing production lines are typicallyslower than the filling of the multiwall pinch bottom bags.Additionally, the sewn bags do not provide an aesthetically pleasing anduseful clean display on the ends of the bags, thus making it difficultfor consumers to identify or find a desired brand quickly when the bagsare displayed on the shelves at the point of sale, such as when they arestacked on top of one another. In addition, the sewn ends requiredpuncturing the plastic bags and thus result in a bag that is not sealed,leading to somewhat reduced shelf-life and possible infestation of thecontents of the bag.

Woven plastic bags have been used and are conventional for certainapplications. An example of a conventional woven plastic bag is providedin U.S. Pat. No. 4,373,979 (“the '979 patent”), issued on Feb. 15, 1983.The '979 patent describes the use of woven strips of highlylongitudinally-oriented, high-density polyethylene or polypropylene in abag construction in which the bag is formed from a seamed tube made ofthe woven plastic material. The seamed tube has gussets on either sideand, when a portion is cut from the rest of the tube, a bag having twoopen, unsealed ends is provided. The '979 patent describes the use ofultrasonic spot welds to seal portions of a bag made of such wovenplastic strips, as opposed to sewing the seams of a bag or using a hotmelt adhesive to seal the gusset forming pleat. The '979 patent ishereby incorporated by reference herein. The '979 patent purports to bean improvement for sealing a plastic bag. As noted in the '979 patent,sewing one end tends to take longer, thus adding time to themanufacturing process. In addition, the sewn ends in a conventional bagtend to be a weak portion of the bag, and a likely location for rips,tearing, and subsequent loss of contents during storing, shipping andhandling. In addition, such bags may not provide sufficient protectionfrom infestation from vermin and/or insects.

Another example of plastic bags is disclosed in U.S. Patent ApplicationPublication Number US 2010/0029455 A1 (“the '455 publication”),published on Feb. 4, 2010, which describes production of web sectionsfrom a flexible web material that is provided with tear-off linesproduced by laser beam processing at the distance of the length of theweb sections to be formed. The tear-off lines weaken the flexible webmaterial, but do not result in complete separation of the web sectionsfrom the web material, which occurs upon tearing the flexible webmaterial. The '455 publication is incorporated by reference herein.

More recently, some types of plastic bags have provided improvements insealing the ends of the bags. For example, in U.S. Pat. No. 6,800,051 B2(“the '051 patent”), issued on Oct. 5, 2004, a process for sealing sidefold sacks made of plastic film is described. According to the '051patent, a web of plastic tubular film is cut to provide a staggereddetachment along a perforation so that one wall (e.g., the front wall)projects beyond the opposing wall (e.g., the back wall). The projectingportion of the first wall is then folded over and sealed to the opposingwall by means of a plastic adhesive such as a polyurethane adhesive orhot melt. The '051 patent is hereby incorporated by reference herein.However, such bags involve plastic films, not woven plastic materials,and therefore are unable to handle the weight loads of conventional bulkbags made of paper and other materials. Such bags are useful for onlycertain lightweight contents, such as bread.

There are a variety of conventional ways of providing for reusableopenings in bags. For example, U.S. Pat. No. 6,478,465 B1 (“the '465patent”), issued Nov. 12, 2002, describes a peelable opening in amultiwall, pinched bottom open mouth bag construction. The '465 patentalso describes the use of an adhesive layer that can be used so that thebag opening is reclosable. The '465 patent is hereby incorporated byreference herein.

In other types of conventional plastic bags, such as those used inretail and grocery stores, the use of weakened portion provided by oneor more perforations in the plastic bag wall is known. A number ofapproaches have been taken in connection with such bags, including thoseshown in U.S. Pat. No. 5,188,235 (the '235 patent), issued Feb. 23,1993, as well as in U.S. Published Patent Application No. 2005/0087542A1 (the '542 application), published Apr. 28, 2005, U.S. Pat. No.5,979,655 (the '655 patent), issued Nov. 9, 1999, and U.S. PublishedPatent Application No. 2006/0072856 (the '856 application), issued Apr.6, 2006. However, none of these bags are woven bags, let alone bags withmultiple layers. The '235 patent, the '655 patent, the '542 application,and the '856 application are hereby incorporated by reference.

Newly developed pinch laminated woven sacks overcome these drawbacks inthe filling and closing operations while allowing an attractive graphicdisplay of the bags' ends at the retail outlet and also providing astrong, durable bag which remains sealed. One major disadvantage of thenewly developed pinch bottom laminated woven sack, however, is that itdoes not allow the consumer or purchaser to quickly and easily open thebag without the use of scissors or knives. There is a need for such apinch bottom laminated woven sack which is easy to open without the useof scissors, knives or other such instruments, and also does not requirethe use of excessive force.

Typically woven bags are sealed with a single or double fold at each endwith tape over the single or double fold, stitching at both ends, or azipper at one end and a single or double fold at the other end. However,opening woven bags has proven difficult, due to the strength of the bag.Therefore, what is needed are woven bags that are easier to open, thatdo not add much to the cost or time to manufacture, and are notsusceptible to inadvertent tearing, punctures, breaking, or the like.

SUMMARY OF THE INVENTION

The present disclosure provides woven plastic bags comprising a weakenedportion, which makes the presently disclosed woven plastic bags easierto open than conventional woven plastic bags.

The present disclosure provides a bag comprising a front wall, a backwall, a first side wall, a second side wall, an interior surface, anexterior surface, a top end, a bottom end, a first layer and a secondlayer, each of the front wall, back wall, first side wall and secondside wall having an interior surface, an exterior surface, a top end anda bottom end, wherein the first layer comprises a woven polymer and thesecond layer comprises a polymer or paper attached to the first layer,and wherein the bag comprises a weakened area located on the front wallof the bag, the first side wall of the bag and the back wall of the bagproximal the top end of the bag. In some embodiments the first layercomprises polypropylene, high density polyethylene, low densitypolyethylene, polyester, or any combination thereof. In otherembodiments the second layer comprises a film. In still otherembodiments the second layer comprises polypropylene, polyethylene,polyethylene terephthalate, polyamide, or any combination thereof orpaper. In yet other embodiments the second layer comprises orientedpolypropylene, biaxially-oriented polypropylene, oriented polyethylene,biaxially-oriented polyethylene, oriented polyethylene terephthalate,biaxially-oriented polyethylene terephthalate, oriented polyamide,biaxially-oriented polyamide, coated paper or any combination thereof.In further embodiments at least a portion of the second layer comprisesa printed area thereon. In still further embodiments the first layer andsecond layer are laminated together. In yet further embodiments thefirst layer and second layer are laminated together using adhesivelamination or extrusion lamination.

In additional embodiments the weakened area comprises a plurality ofperforations that penetrate through at least a portion of the front wallof the bag, the first side wall of the bag and the back wall of the bag.In some embodiments the plurality of perforations forms a line. Invarious embodiments the plurality of perforations forms a line thatextends from any position on the front wall of the bag, for exampleabout 5%, about 10%, about 15%, about 20%, about 25%, about 30%, about35%, about 40%, about 45%, about 50%, about 55%, about 60%, about 65%,about 70%, about 75%, about 80%, about 85%, about 90%, about 95%, about97%, about 98% or about 99% of a distance across the front wall of thebag, across the first side wall of the bag, to any position on the backwall of the bag, for example about 5%, about 10%, about 15%, about 20%,about 25%, about 30%, about 35%, about 40%, about 45%, about 50%, about55%, about 60%, about 65%, about 70%, about 75%, about 80%, about 85%,about 90%, about 95%, about 97%, about 98% or about 99% of a distanceacross the back wall of the bag. In other embodiments the plurality ofperforations forms a wave pattern. In further embodiments the pluralityof perforations forms a zigzag pattern. In still further embodiments theweakened area comprises a deformation in least a portion of the frontwall of the bag, the first side wall of the bag and the back wall of thebag. In yet further embodiments the weakened area further comprises ascoring mark. In certain embodiments each of the first layer and thesecond layer of the bag comprise a weakened portion. In still otherembodiments the back wall of the bag comprises a seam.

In certain embodiments the top end of the back wall projects furtherthan the top end of a portion of the first side wall proximal to theback wall and the top end of a portion of the second side wall proximalto the back wall, the top end of a portion of the first side wallproximal to the back wall and the top end of a portion of the secondside wall proximal to the back wall projects further than the top end ofa portion of the first side wall proximal to the front wall and the topend of a portion of the second side wall proximal to the front wall, andthe top end of a portion of the first side wall proximal to the frontwall and the top end of a portion of the second side wall proximal tothe front wall projects further than the top end of the front wall. Inother embodiments at least a portion of the bottom end of the front wallprojects further than the bottom end of a portion of the first side wallproximal to the front wall and the bottom end of a portion of the secondside wall proximal to the front wall, the bottom end of a portion of thefirst side wall proximal to the front wall and the bottom end of aportion of the second side wall proximal to the front wall projectfurther than the bottom end of a portion of the first side wall proximalto the back wall and the bottom end of a portion of the second side wallproximal to the back wall, and the bottom end of a portion of the firstside wall proximal to the back wall and the bottom end of a portion ofthe second side wall proximal to the back wall project further than thebottom end of the rear wall. In further embodiments the top end of aportion of the first side wall proximal to the back wall and the top endof a portion of the first side wall proximal to the front wall areseparated by an angled cut, and the bottom end of a portion of the firstside wall proximal to the back wall and the bottom end of a portion ofthe first side wall proximal to the front wall are separated by anangled cut.

In additional embodiments the portion of the bottom end of the frontwall that projects further than the bottom end of the first side walland the bottom end of the second side wall, and the portion of thebottom end of the first side wall and the bottom end of the second sidewall that project further than the bottom end of the rear wall aresealed to the outer surface of the bottom end of the rear wall. Incertain embodiments the bottom end of the bag is sealed using anadhesive sealing, heat sealing, adhesive lamination, extrusionlamination, stitching, ultrasonic energy, pressure, tape, or anycombination thereof. In some embodiments the bottom end of the bag issealed using adhesive-to-adhesive sealing or adhesive-to-bag sealing. Infurther embodiments the bottom end of the front wall, the bottom end ofthe first side wall, the bottom end of the rear wall and the bottom endof the second side wall each project the same distance. In still furtherembodiments at least a portion of a single fold of the bottom end of thebag is sealed to the outer surface of the front wall or the outersurface of the rear wall of the bag. In yet further embodiments at leasta portion of a double fold of the bottom end of the bag is sealed to theouter surface of the front wall or the outer surface of the rear wall ofthe bag.

In other embodiments the top end of the front wall, the top end of thefirst side wall, the top end of the rear wall and the top end of thesecond side wall each project the same distance. In certain embodimentsat least a portion of the bottom end of the front wall projects furtherthan the bottom end of a portion of the first side wall proximal to thefront wall and the bottom end of a portion of the second side wallproximal to the front wall, the bottom end of a portion of the firstside wall proximal to the front wall and the bottom end of a portion ofthe second side wall proximal to the front wall project further than thebottom end of a portion of the first side wall proximal to the back walland the bottom end of a portion of the second side wall proximal to theback wall, and the bottom end of a portion of the first side wallproximal to the back wall and the bottom end of a portion of the secondside wall proximal to the back wall project further than the bottom endof the rear wall. In still other embodiments the portion of the bottomend of the front wall that projects further than the bottom end of thefirst side wall and the bottom end of the second side wall, and theportion of the bottom end of the first side wall and the bottom end ofthe second side wall that project further than the bottom end of therear wall are sealed to the outer surface of the bottom end of the rearwall. In additional embodiments the bottom end of the front wall, thebottom end of the first side wall, the bottom end of the rear wall andthe bottom end of the second side wall each project the same distance.In certain embodiments the top end and the bottom end of the bag aresealed, and wherein the bag comprises at least ten pounds by weight of afilling material.

In some embodiments the bag further comprises a third layer comprising apolymer between the first layer and the second layer. In certainembodiments the third layer comprises a woven polymer. In otherembodiments the third layer comprises polypropylene, high densitypolyethylene, low density polyethylene, polyester, or any combinationthereof. In further embodiments the third layer comprises a polymericfilm. In additional embodiments the third layer comprises polypropylene,polyethylene, polyethylene terephthalate, polyamide, or any combinationthereof. In still other embodiments each of the first layer, the secondlayer and the third layer of the bag comprise a weakened portion.

In further embodiments the bag comprises printing on the front wall, thefirst side wall, the back wall, the second side wall, the first end, thesecond end, or any combination thereof. In still further embodiments atleast portions of the exterior surfaces of each of the front wall andthe back wall comprise a plurality of discrete areas further comprisingprinting thereon. In yet further embodiments a portion of the front walland a portion of the back wall combine to form a discrete portion of thebag located at or near either the top end or the bottom end, wherein thediscrete portion of the bag comprises printing thereon.

These and other objects of the invention will be apparent to thoseskilled in the art from the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings are included to further demonstrate certainaspects and embodiments of the present invention. The invention may bebetter understood by reference to one or more of these drawings incombination with the detailed description of specific embodimentspresented herein.

FIG. 1 shows an outline of a step cut bag with a weakened area near thetop end of the bag comprising a line of perforations extending from thefront panel of the bag across the first side panel of the bag to theback panel of the bag according to one embodiment of the presentdisclosure.

FIG. 2 shows the top portion of the bag of FIG. 1 after closing the topend of the bag.

FIG. 3 shows the first step in opening the closed bag from FIG. 2.

FIG. 4 shows the second step in opening the closed bag from FIG. 2.

FIG. 5 shows the third step in opening the closed bag from FIG. 2.

FIG. 6 shows the fourth step in opening the closed bag from FIG. 2.

FIG. 7 shows the top portion of the bag of FIG. 1 after closing the topend of the bag and a location for optional application of adhesive tokeep the top portion of the gusseted portion of the first side panelclosed.

FIG. 8 shows an outline of a step cut bag with a weakened area near thetop end of the bag comprising a line of perforations extending from thefront panel of the bag across the first side panel of the bag to theback panel of the bag, and angled corners at the top and bottom of theportions of the first and second side panels on either side of thegusset fold, according to one embodiment of the present disclosure.

FIG. 9 shows an outline of a bag with a step cut top end and a flush cutbottom end, and a weakened area near the top end of the bag comprising aline of perforations extending from the front panel of the bag acrossthe first side panel of the bag to the back panel of the bag accordingto one embodiment of the present disclosure.

FIG. 10 shows an outline of a bag with a flush cut top end and a flushcut bottom end, and a weakened area near the top end of the bagcomprising a line of perforations extending from the front panel of thebag across the first side panel of the bag to the back panel of the bagaccording to one embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1, a planar view of an embodiment of a substantiallyflat sheet of material from which a “step cut” bag 1 is to be formed isshown. Shown on the sheet are front wall 2, rear wall 3, seam 4, firstside wall 5 having gusset portion 6, and second side wall 7 havinggusset portion 8. As shown in FIG. 1, the bag 1 has a first or top end 9and a second or bottom end 10, and thus each of the front wall 2, rearwall 3, first side wall 5 and second side wall 7 has a first or top endand a second or bottom end. It will be apparent, however, that theorientation of the bag ends 9 and 10 are unimportant and the “top” and“bottom” references are useful but may change depending upon theorientation from which one views the bag. Bag 1 is considered a “stepcut” bag because the front wall 2, the first side wall 5 and the secondside wall 7, and the rear wall 3 are cut so that the front wall 2, thefirst side wall 5 and the second side wall 7, and the rear wall 3 havedifferent lengths on one end (or both ends) of the bag. As shown in FIG.1, the first side wall 5 and the second side wall 7 are cut to differentlengths on either side of the gusset portion 6 and 8, respectively. Asshown in FIG. 1 the first end 9 of bag 1 has portions 3 a and 3 b of therear wall 3 of the bag that extend further from the body of the bag 1than do portions 5 a and 7 a of the first side wall 5 and second sidewall 7, respectively, which in turn extend further from the body of thebag 1 than do portions 5 b and 7 b of the first side wall 5 and secondside wall 7, respectively, which in turn extend further from the body ofthe bag 1 than does the top end of the front wall 2 of the bag 1. Inaddition, the bottom end of the front wall 2 at the second end 10 of bag1 extends further from the body of the bag 1 than do portions 5 c and 7c of the first side wall 5 and second side wall 7, respectively, whichin turn extend further from the body of the bag 1 than do portions 5 dand 7 d of the first side wall 5 and second side wall 7, respectively,which in turn extend further from the body of the bag 1 than do portions3 c and 3 d the bottom end of the rear wall 3 of the bag 1. Therefore,in the embodiment shown in FIG. 1 both of the ends of the bag 1 have a“step cut.” Also shown is weakened portion 20, which in this embodimentis near the first end 9 of the bag 1 and comprises a plurality ofperforations 21 extending from a first end 21 a on the front wall 2 ofthe bag 1 across the first side wall 5 of the bag 1 to a second end 21 bon the rear wall 3 of the bag 1. The weakened area is generally on ornear the fold line (not shown) for closing or sealing the first end 9 ofthe bag 1. This weakened portion can be opened with less force thanrequired to open or tear other portions of the bag 1.

Referring to FIG. 2, the upper portion of the bag 1 from FIG. 1 is shownafter sealing the first end 9 of the bag 1. Visible in FIG. 2 is frontwall 2, back wall 3 having portions 3 a and 3 b, seam 4, first side wall5 having gusset portion 6, and weakened portion 20 comprising aplurality of perforations 21 terminating at second end 21 b.

Bag 1 can be opened as shown in FIG. 3 through FIG. 6. FIG. 3 once againshows the upper portion of the bag 1 from FIG. 2, and visible is frontwall 2, back wall 3 having portions 3 a and 3 b, seam 4, first side wall5 having gusset portion 6, and weakened portion 20 comprising aplurality of perforations 21 terminating at second end 21 b. Bag 1 isopened by initially pulling on the portions 3′ and 3″ of the rear wall 3on both sides of the plurality of perforations 21, which creates a tearin the weakened portion 20 of the bag 1 and begins separating theportions of the first side wall 5 that are separated by the gussetportion 6. In FIG. 4 the portions 3′ and 3″ of the rear wall 3 on bothsides of the plurality of perforations 21 are further pulled apart,resulting in the expansion of the tear in the weakened portion 20 towardthe second end 21 b of the plurality of perforations 21. Additionallyvisible in FIG. 4 are front wall 2, back wall 3 having portions 3 a and3 b, seam 4, and first side wall 5 having gusset portion 6. In FIG. 5the portions 3′ and 3″ of the rear wall 3 on both sides of the pluralityof perforations 21 are pulled completely apart, resulting in theexpansion of the tear in the weakened portion 20 further toward thesecond end 21 b of the plurality of perforations 21 and to the first end21 a of the plurality of perforations (not visible in FIG. 5). Thisresults in uncovering the top end 6 a of the gusset portion 6 of thefirst side wall 5, which can then be pulled open. Additionally visiblein FIG. 5 are front wall 2, back wall 3 having portions 3 a and 3 b, andseam 4. In FIG. 6 the plurality of perforations 21 are pulled completelyapart, resulting in the expansion of the tear in the weakened portion 20to the second end 21 b of the plurality of perforations 21. This resultsin a large opening in bag 1 that can be used to pour out the contents ofthe bag 1. Additionally visible in FIG. 6 are front wall 2, back wall 3having portions 3 a, 3 b, 3′ and 3″, seam 4, first side wall 5 andgusset portion 6 having a top end 6 a.

Referring to FIG. 7, the upper portion of the bag 1 from FIG. 1 is shownafter sealing the first end 9 of the bag 1, with optional adhesive 30located near the top end of the first side wall 5, which serves to keepthe top end of the first side wall 5 closed (see arrows). Although notvisible in FIG. 7, the optional adhesive can also be applied near thetop end of the second side wall. Although shown as a spot in FIG. 7, theadhesive can be applied in any manner that results in the closure of thetop end of the first side wall 5, for example as a strip that runs fromthe edge of the intersection of the first side wall 5 and the back wall3 to the edge of the intersection of the first side wall 5 and the frontwall 2. Also visible in FIG. 7 is front wall 2, back wall 3 havingportions 3 a and 3 b, seam 4, first side wall 5 having gusset portion 6,and weakened portion 20 comprising a plurality of perforations 21terminating at second end 21 b.

Once the bag 1 is sealed at one end, it can be filled with the desiredmaterials. For example, it has been found that a bag 1 with dimensionsof 16.5 inches by 6.5 inches by 39.5 inches can durably hold up to aboutfifty five (55) pounds of material without showing undue stress, unduetearing, undue breakage, undue deformation, or leakage or the like. Itis believed that any bulk material can be contained by bag 1, and incertain embodiments the contents can weigh up to 100 pounds or sowithout undue risk of tearing or damage to bag 1. Once the bag 1 isfilled, the second end typically needs to be sealed. The second end ofthe bag 1 can be sealed in a similar manner as that described above.Alternatively, the bag 1 can have its second end sealed by conventionalmeans such as sewing. Still another approach is to stitch the secondend, and then seal the second end in a manner like that described above(not shown). Although not shown, those skilled in the art willunderstand and appreciate that a second end of bag 1 can be sealed usingany conventional technique once bag 1 has been filled with the selectedamount of the desired material.

Referring to FIG. 8, a planar view of an embodiment of a substantiallyflat sheet of material from which a “step cut” bag 101 is to be formedis shown. Shown on the sheet are front wall 102, rear wall 103, seam104, first side wall 105 having gusset portion 106, and second side wall107 having gusset portion 108. As shown in FIG. 8, the bag 101 has afirst or top end 109 and a second or bottom end 110, and thus each ofthe front wall 102, rear wall 103, first side wall 105 and second sidewall 107 has a first or top end and a second or bottom end. It will beapparent, however, that the orientation of the bag ends 109 and 110 areunimportant and the “top” and “bottom” references are useful but maychange depending upon the orientation from which one views the bag. Bag101 is considered a “step cut” bag because the front wall 102, the firstside wall 105 and the second side wall 107, and the rear wall 103 arecut so that the front wall 102, the first side wall 105 and the secondside wall 107, and the rear wall 103 have different lengths on one end(or both ends) of the bag. As shown in FIG. 8, the first side wall 105and the second side wall 107 are cut to different lengths on either sideof the gusset portion 106 and 108, respectively. As shown in FIG. 8 thefirst end 109 of bag 101 has portions 103 a and 103 b of the rear wall103 of the bag that extend further from the body of the bag 101 than doportions 105 a and 107 a of the first side wall 105 and second side wall107, respectively, which in turn extend further from the body of the bag101 than do portions 105 b and 107 b of the first side wall 105 andsecond side wall 107, respectively, which in turn extend further fromthe body of the bag 101 than does the top end of the front wall 102 ofthe bag 101. In addition, the bottom end of the front wall 102 at thesecond end 110 of bag 101 extends further from the body of the bag 101than do portions 105 c and 107 c of the first side wall 105 and secondside wall 107, respectively, which in turn extend further from the bodyof the bag 101 than do portions 105 d and 107 d of the first side wall105 and second side wall 107, respectively, which in turn extend furtherfrom the body of the bag 101 than do portions 103 c and 103 d the bottomend of the rear wall 103 of the bag 101. Therefore, in the embodimentshown in FIG. 8 both of the ends of the bag 101 have a “step cut.” Inaddition, the portions 105 a and 105 b, 107 a and 107 b, 105 c and 105d, and 107 c and 107 d are not separated by a straight line, but ratheran angled cut (see circles). Although in FIG. 8 this cut is shown asabout 45°, the angle can vary in different embodiments (not shown). Thisangled cut serves to further prevent leakage of contents out of the bag,or infestation of organisms into the contents of the bag. Also shown isweakened portion 120, which in this embodiment is near the first end 109of the bag 101 and comprises a plurality of perforations 121 extendingfrom a first end 121 a on the front wall 102 of the bag 101 across thefirst side wall 105 of the bag 101 to a second end 121 b on the rearwall 103 of the bag 101. The weakened area is generally on or near thefold line (not shown) for closing or sealing the first end 109 of thebag 101. This weakened portion can be opened with less force thanrequired to open or tear other portions of the bag 101.

Referring to FIG. 9, a planar view of an embodiment of a substantiallyflat sheet of material from which a bag 201 is to be formed is shown.Shown on the sheet are front wall 202, rear wall 203, seam 204, firstside wall 205 having gusset portion 206, and second side wall 207 havinggusset portion 208. As shown in FIG. 9, the bag 201 has a first or topend 209 and a second or bottom end 210, and thus each of the front wall202, rear wall 203, first side wall 205 and second side wall 207 has afirst or top end and a second or bottom end. It will be apparent,however, that the orientation of the bag ends 209 and 210 areunimportant and the “top” and “bottom” references are useful but maychange depending upon the orientation from which one views the bag. Thetop end 209 of bag 201 is has a “step cut” because the front wall 202,the first side wall 205 and the second side wall 207, and the rear wall203 are cut so that the front wall 202, the first side wall 205 and thesecond side wall 207, and the rear wall 203 have different lengths. Asshown in FIG. 9, the first side wall 205 and the second side wall 207are cut to different lengths on either side of the gusset portion 206and 208, respectively. As shown in FIG. 9 the first end 209 of bag 201has portions 203 a and 203 b of the rear wall 203 of the bag 201 thatextend further from the body of the bag 201 than do portions 205 a and207 a of the first side wall 205 and second side wall 207, respectively,which in turn extend further from the body of the bag 201 than doportions 205 b and 207 b of the first side wall 205 and second side wall207, respectively, which in turn extend further from the body of the bag201 than does the top end of the front wall 202 of the bag 201. In theembodiment shown in FIG. 9, the bottom end of the front wall 202, thefirst side wall 205, the second side wall 207, and the rear wall 203 atthe second end 210 of bag 201 each extend the same distance from thebody of the bag 201. Therefore, in the embodiment shown in FIG. 9 thebottom end 210 of the bag 201 has a “flush cut.” Although not shown, incertain embodiments the top end of the bag can be flush cut, and thebottom end of the bag can be step cut. Also shown is weakened portion220, which in this embodiment is near the first end 209 of the bag 201and comprises a plurality of perforations 221 extending from a first end221 a on the front wall 202 of the bag 201 across the first side wall205 of the bag 201 to a second end 221 b on the rear wall 203 of the bag201. The weakened area is generally on or near the fold line (not shown)for closing or sealing the first end 209 of the bag 201. This weakenedportion can be opened with less force than required to open or tearother portions of the bag 201.

Referring to FIG. 10, a planar view of an embodiment of a substantiallyflat sheet of material from which a flush cut bag 301 is to be formed isshown. Shown on the sheet are front wall 302, rear wall 303, seam 304,first side wall 305 having gusset portion 306, and second side wall 307having gusset portion 308. As shown in FIG. 10, the bag 301 has a firstor top end 309 and a second or bottom end 310, and thus each of thefront wall 302, rear wall 303, first side wall 305 and second side wall307 has a first or top end and a second or bottom end. It will beapparent, however, that the orientation of the bag ends 309 and 310 areunimportant and the “top” and “bottom” references are useful but maychange depending upon the orientation from which one views the bag. Thetop end 309 of bag 301 has a “flush cut” because the front wall 302, thefirst side wall 305 and the second side wall 307, and the rear wall 303are cut to the same length. In the embodiment shown in FIG. 10, thebottom end of the front wall 302, the first side wall 305, the secondside wall 307, and the rear wall 303 at the second end 310 of bag 301each extend the same distance from the body of the bag 301. Therefore,in the embodiment shown in FIG. 10 the bottom end 310 of the bag 301also has a “flush cut.” Also shown is weakened portion 320, which inthis embodiment is near the first end 309 of the bag 301 and comprises aplurality of perforations 321 extending from a first end 321 a on thefront wall 302 of the bag 301 across the first side wall 305 of the bag301 to a second end 321 b on the rear wall 303 of the bag 301. Theweakened area is generally on or near the fold line (not shown) forclosing or sealing the first end 309 of the bag 301. This weakenedportion can be opened with less force than required to open or tearother portions of the bag 301.

Those skilled in the art will understand and appreciate that the bagaccording to the invention may vary in size, dimensions, and shapewithout departing from the scope of the invention, and that theforegoing description of the preferred embodiments is not intended tolimit the scope of the invention as defined by the claims. For example,those skilled in the art will understand and appreciate that theforegoing bag 1 can have sealed and sewn ends in a tubular bag with sidegussets as shown, or a block bottom and top, or a combination thereof,although not shown. Those skilled in the art will also appreciate that aweakened portion or area can be provided in a number of ways that mayvary from those expressly described and shown, such as by stressingportions of the bag wall with or without deforming or perforating same,as well as varying the size, number, depth, and/or pattern ofperforations and/or deformations in a bag wall. Similarly, those skilledin the art will understand that the bag 1 may be provided with are-usable opening (not shown). Such features are conventional with priorart bags. Similarly, those skilled in the art will appreciate that termssuch as “front” and “rear,” and “top” and “bottom,” are useful indescribing a bag, but essentially depend on a bag's orientation whensuch terms are used, and are therefore not limiting as to a bag'sorientation.

We claim:
 1. A bag comprising: a front wall, a back wall, a first sidewall further comprising a first gusset, a second side wall furthercomprising a second gusset, a top end, and a bottom end; wherein each ofthe front wall, the back wall, the first side wall, and the second sidewall respectively further comprise: an interior surface, an exteriorsurface, a top end, and a bottom end; wherein each of the front wall,the back wall, the first side wall, and the second side wall comprise afirst layer and a second layer, with the first layer and second layerlaminated together; wherein the first layer comprises woven polymerstrips consisting essentially of oriented polypropylene, and the secondlayer comprises an oriented polymer film consisting essentially ofpolypropylene; wherein the bag further comprises a plurality ofperforations proximal the top end of the bag that define a line parallelto the top end of the bag, the line extending from a point on the frontwall of the bag, across the first side wall of the bag, and to a pointon the back wall of the bag; wherein each of the plurality ofperforations penetrates through at least a portion of the first layer ora portion of the second layer; wherein the top end of the back wallextends further than a first portion of the first side wall and thesecond side wall at respective top ends, the first portion beingproximal to the back wall; wherein the first portion of the first sidewall and the second side wall extends further than a second portion ofthe first side wall and the second side wall at respective top ends, thesecond portion being proximal to the front wall; wherein the secondportion of the first side wall and the second side wall extends furtherthan the top end of the front wall; and wherein the first portion of thefirst side wall and the second portion of the first side wall areseparated by a first angled cut, and the first portion of the secondside wall and the second portion of the second side wall are separatedby a second angled cut.
 2. The bag according to claim 1, wherein atleast a portion of the exterior surfaces comprises a printed area. 3.The bag according to claim 1, wherein the first layer and the secondlayer are laminated together using adhesive lamination.
 4. The bagaccording to claim 1, wherein the first layer and the second layer arelaminated together using extrusion lamination.
 5. The bag according toclaim 1, wherein the line extends from 20% of a first length across thefront wall of the bag and the first side wall of the bag to 50% of asecond length of a width of the back wall of the bag.
 6. The bagaccording to claim 1, wherein the bag further comprises a deformation inthe front wall of the bag, the first side wall of the bag and the backwall of the bag.
 7. The bag according to claim 6, wherein the bagfurther comprises a scoring mark.
 8. The bag according to claim 1,wherein the back wall of the bag comprises a seam.
 9. The bag accordingto claim 1, wherein each of the front wall, the back wall, the firstside wall, and the second side wall are formed using a third layerbetween the first layer and the second layer, the third layer laminatingthe first layer to the second layer.
 10. The bag accordingly to claim 9,wherein each of the plurality of perforations penetrates through atleast a portion of the third layer.
 11. The bag according to claim 9,wherein the third layer comprises a polymer film consisting essentiallyof polypropylene.
 12. The bag according to claim 1, wherein a firstportion of the front wall, at the bottom end of the front wall, extendsfurther than a third portion of the first side wall and the second sidewall, respectively, the third portion being at the bottom end andproximal to the front wall; wherein the third portion of the first sidewall and the second side wall extends further than a fourth portion ofthe first side wall and the second side wall, respectively, the fourthportion being at the bottom end and proximal to the back wall; andwherein the fourth portion of the first side wall and the second sidewall, respectively, extends further than the bottom end of the backwall.
 13. The bag according to claim 12, wherein the third portion andthe fourth portion of the first side wall are separated by a thirdangled cut; and wherein the third portion and the fourth portion of thesecond side wall are separated by a fourth angled cut.
 14. The bagaccording to claim 12, wherein the first portion of the front wall, andthe third portion of the first side wall and the second side wall arejoined to the exterior surface of the back wall using a sealingoperation.
 15. The bag according to claim 1, wherein a first portion ofthe front wall, at the bottom end of the front wall, extends furtherthan a third portion of the first side wall and the second side wall,respectively, the third portion being at the bottom end and proximal tothe front wall; wherein the third portion of the first side wall and thesecond side wall and a fourth portion of the first side wall and thesecond side wall, respectively, extend the same distance, the fourthportion being at the bottom end and proximal to the back wall; andwherein the fourth portion of the first side wall and the second sidewall, respectively, extends further than the bottom end of the backwall.
 16. The bag according to claim 1 wherein the plurality ofperforations enables opening the bag by tearing the plurality ofperforations using less force than tearing other portions of the bag.17. A bag comprising: a front wall, a back wall, a first side wallfurther comprising a first gusset, a second side wall further comprisinga second gusset, a top end, and a bottom end; wherein each of the frontwall, the back wall, the first side wall, and the second side wallrespectively further comprise: an interior surface, an exterior surface,a top end, and a bottom end; wherein each of the front wall, the backwall, the first side wall, and the second side wall comprise a firstlayer and a second layer; wherein the first layer comprises wovenpolymer strips consisting essentially of oriented polyethylene, thesecond layer comprises an oriented polymer film consisting essentiallyof polyethylene, and the first layer and the second layer are laminatedtogether; wherein the bag further comprises a plurality of perforationslocated on the front wall of the bag, the first side wall of the bag,and the back wall of the bag, proximal the top end of the bag; whereineach of the plurality of perforations penetrates through at least aportion of the first layer or a portion of the second layer; wherein theplurality of perforations define a line that is parallel to the top endof the bag, the line extending from a point on the front wall of thebag, across the first side wall of the bag, and to a point on the backwall of the bag; wherein the top end of the back wall extends furtherthan a first portion of the first side wall and the second side wall atrespective top ends, the first portion being proximal to the back wall;wherein the first portion of the first side wall and the second sidewall extends further than a second portion of the first side wall andthe second side wall at respective top ends, the second portion beingproximal to the front wall; wherein the second portion of the first sidewall and the second side wall extends further than the top end of thefront wall; and wherein the first portion of the first side wall and thesecond portion of the first side wall are separated by a first angledcut, and the first portion of the second side wall and the secondportion of the second side wall are separated by a second angled cut.18. The bag according to claim 17, wherein each of the front wall, theback wall, the first side wall, and the second side wall comprise athird layer between the first layer and the second layer, the thirdlayer laminating the first layer to the second layer.
 19. The bagaccordingly to claim 18, wherein each of the plurality of perforationspenetrates through at least a portion of the third layer.
 20. The bagaccording to claim 18, wherein the third layer comprises a polymer filmconsisting essentially of polyethylene.
 21. The bag according to claim17, wherein the plurality of perforations enables opening the bag bytearing the plurality of perforations using less force than tearingother portions of the bag.